PowerBox PBX 180. Installation and Users Guide

Transcription

1 PowerBox PBX 180 Installation and Users Guide Firmware and Tool Version 060 7/14/2015

2 Table of Contents Table of Contents 1 Introduction Hardware Software Installation Software Installation from a CD Software Installation from web-download PC Software and Firmware Releases Connection to System Wiring Harness Main Menu File Device Interface Options Help Functions Overview Units Events Miscellaneous Special Functions Counters Status Events Monitor Output Diagnostics Inputs Digital Inputs Analogue Inputs CAN Inputs Outputs Tri-State Outputs Low Power Outputs Low Power PWM Outputs High Power Outputs Very High Power High Power PWM Outputs Sensor Supplies Wiper Outputs Warning Lamp Fault Reset CAN Bus Data Bus CAN Monitor CAN Export / 60 PowerBox PBX 180 Bosch Motorsport

3 Table of Contents 9 Pin Configuration Connector 1 - Battery Power Supply Connector 2 - High Power Outputs Connector 3 - Low Power Outputs Connector 4 - Signal and Inputs Specifications Inputs Outputs Maximum Current Rating Temperatures Communication Power Supply Dimensions Bosch Motorsport PowerBox PBX / 60

4 1 Introduction 1 Introduction The Bosch PowerBox PBX 180 takes the whole Power Control Module concept much further than existing modules. It provides an effective and inspired alternative to conventional relays, circuit breakers, fuses and wires that can so often be a tangle of complexity and untidiness around a typical racing car s power junction box. Bosch PowerBox PBX 180 is a compact and light weight module, measuring 191 x 176 x 36 mm (excluding the Autosport connectors). Bosch PowerBox PBX 180 has a maximum of 48 power channels, arranged as: 26 normal power channels, each 8 A continuous power supply. 2 normal and wiper motor power channels, each 8 A continuous power supply. 4 low power channels with PWM, each 8 A continuous power supply. 12 high power channels, each 20 A continuous power supply. 2 high power channels with PWM, each 20 A continuous power supply. 2 very high power channels, each 20 A continuous power supply. All outputs are protected against reversed battery polarity. Current draw can be measured on all 48 power channels: From 50 ma on 4 low power channels. From 200 ma on all other channels. Any of these channels can be controlled by various types and combinations of inputs: 14 digital inputs with automatic sensing of high, low and floating potential. 16 analogue 0 to 12 V sensor inputs with 16 bit resolution. 64 individually programmable CAN inputs, 11 or 29 bit identifiers, with bit operator. 4 individually programmable CAN busses. Bosch PowerBox PBX 180 is also equipped with 4 tri-state outputs. A tri-state output is only for use as an ECU trigger. Do not connect any of these four channels to any output load. In addition to the 4 CAN bus, Bosch PowerBox PBX 180 is also equipped with a LIN bus. Bosch PowerBox PBX 180 can be configured as either a LIN bus master or slave. Use the LIN bus for example to control the alternator charge current or to control the wiper motor. Instead of using a conventional control program, Bosch PowerBox PBX 180 benefits from a multi-tasking operating system, allowing simultaneous executions of operations. Furthermore, Bosch PowerBox PBX 180 is equipped with a real time clock and also has a built-in data recording facility with a memory capacity of minimum 2 GB. Data is downloaded via the Ethernet connection. 4 / 60 PowerBox PBX 180 Bosch Motorsport

5 Introduction 1 Please note that the maximum recommended current draw per channel is limited by the connector contacts - not by Bosch PowerBox PBX 180s driver stages. We have rated the individual channel s current draw in relation to the connector manufacturer s specifications. Bosch PowerBox PBX 180 is programmed to shut overloaded channels down if the current draw and internal junction temperatures exceed pre-set levels. Board temperatures are monitored and can be exported via CAN. For normal running conditions, the user can set limits for inrush current level and time; the fused thresholds for continuous current draw plus the number of retries and retry time intervals for each output channel. A manual reset function of all overloaded channels is also available. The current draws and channel status can be logged internally and exported via one of the four available CAN bus. Please note that the PCM is not intended to be used to control safety-critical systems on a vehicle, such as ABS braking, power steering, etc. Bosch Motorsport shall not be responsible for any incidental or consequential damages or injuries that may occur if the unit is used to control these, or similar, safety-critical systems. Bosch Motorsport PowerBox PBX / 60

6 2 Hardware 2 Hardware The Bosch PowerBox PBX 180 enclosure is CNC machined to the highest standards. The two parts of the casing are sealed by an O-ring, located in a recess in the main half. A lip in the lid presses on the O-ring and assures a water tight sealing. The connectors are individually sealed. Connector #1 is a Deutsch Autosport Heavy Duty single pin connector, type ASHD PN. This is a specially developed connector, designed to conduct very high currents with very low losses and to withstand high temperatures. We recommend using a 35 sq.mm heavy duty battery cable as the main power supply. The mating connector on the wiring loom must be ASHD S C35. Connector #2 is a Deutsch Autosport connector, type AS SN. This connector has 16 size AWG 16 contacts and each contact is designed to handle a maximum current of 20 A. The mating connector on the wiring loom must be AS PN. Connector #3 is a Deutsch Autosport connector, type AS SA. It has a different keyway to connector 2, preventing incorrect mating of connectors. This connector has 37 size AWG 20 contacts and 2 size AWG 16 contacts. Each AWG 20 contact is designed to handle max 8 A current. The two size AWG 16 contacts (pins m and r) in this connector are power ground connections and must be connected to earth. The mating connector on the wiring loom must be AS PA (yellow coding). Connector #4 is a Deutsch Autosport connector, type AS SN. This connector has 55 size AWG 22 contacts and is used for signal, sensor supplies and data connections. The mating connector on the wiring loom must be AS PN. 6 / 60 PowerBox PBX 180 Bosch Motorsport

7 Software Installation Software Installation The software can be installed either from a software CD, provided with the Bosch PowerBox PBX 180 or downloaded from our web site Software Installation from a CD Place the CD in your PC s CD drive. The installation starts automatically. Follow the instructions given on-screen to complete the installation. A manual installation is possible by exploring the installation CD and double clicking on the file called SETUP Bosch PowerBox PBX 180 vx_yz.exe where X_YZ refers to the software release version. 3.2 Software Installation from web-download It is possible to download the Bosch PowerBox PBX 180 software from our web site. Go to and select the Software tab. When you have downloaded the Bosch PowerBox PBX 180 software, open the folder where you saved the file and double click on the installation file. This file is called SETUP Bosch PowerBox PBX 180 vx_yz.exe where X_YZ refers to the software release version. 3.3 PC Software and Firmware Releases Each new release of Bosch PowerBox PBX 180 firmware requires an updated, specific PC tool release. Each new release of the PC tool is backwards compatible, meaning that it will support earlier Bosch PowerBox PBX 180 firmware releases. 3.4 Connection to System Communication between the PC tool and a Bosch PowerBox PBX 180 is established via any of the 4 available CAN connections, using a USB CAN interface. Connection is automatic; no user commands are normally required. Three different versions of interfaces can be used: CAN USB Adapter (Lawicel) Peak CAN Adapter (Peak Systems, recommended) EFI Technology CAN Adapter If you disconnect from the system, communication will be re-established when you plug the cable in again. Bosch Motorsport PowerBox PBX / 60

8 3 Software Installation 3.5 Wiring Harness Bosch Motorsport can supply complete, custom made wiring harnesses for bespoke installations. Our harnesses are manufactured by specialists, using only the best suitable materials for use in the harsh environment of a modern racing or rally car. 8 / 60 PowerBox PBX 180 Bosch Motorsport

9 Main Menu 4 4 Main Menu The PC tool has five main menu sections: File Device Interface Options Help File You can open an existing configuration file by clicking on FILE and then select OPEN. Use F2 as a hot key to open a new configuration file. You can save a configuration file on your PC by clicking on FILE, then SAVE. Now select the folder where you want to save the file, type a file name and click OK. Use F3 as a hot key to save a configuration file. Click on Save Hex to save a configuration file as a hex file. Use F4 as a hot key for this function. Admin is a Bosch PowerBox PBX 180 section only. Click on EXIT to close the Bosch PowerBox PBX 180 tool. Use F7 as a hot key to close the program. Device Read You can read the Bosch PowerBox PBX 180 configuration file by clicking on READ in the menu DEVICE. Use F8 as a hot key to read the configuration from Bosch PowerBox PBX 180. Bosch Motorsport PowerBox PBX / 60

10 4 Main Menu Write You can upload a new configuration from the PC tool to Bosch PowerBox PBX 180 by clicking on WRITE. Use F9 as a hot key to write a new configuration file to Bosch PowerBox PBX 180. Once the new configuration file has been transmitted to the Bosch PowerBox PBX 180, the module is re-booted automatically. Note that a configuration file can only be uploaded if the battery supply voltage is above 10 V. It is not possible to send a configuration file to Bosch PowerBox PBX 180 if more than one event controls a single output. Please see section 5.3. Reset Use F10 as a hot key to re-boot the Bosch PowerBox PBX 180, reading the new settings. Bosch PowerBox PBX 180 is automatically reset after a firmware update or after uploading a new configuration. Firmware Click on FIRMWARE to update the Bosch PowerBox PBX 180 firmware. Once the firmware has been transmitted, Bosch PowerBox PBX 180 performs an automatic re-boot. A new firmware includes new Bosch PowerBox PBX 180 features and it is essential that you also update your PC tool, too. The latest PC toll released is always backwards compatible. Use F6 as a hot key to update firmware. Manual Output Mode Manual Output Mode is used to check the switching and current draw of any output, manually controlled by the PC tool. When power is applied to Bosch PowerBox PBX 180 it starts by default in automatic mode. In Manual Output Mode all events are deactivated and no automatic or programmed switching is possible. Instead, it is only possible to switch each single output ON and OFF using the PC tool. Go to section OUTPUTS for further information. Automatic Output Mode By clicking Automatic Output Mode Bosch PowerBox PBX 180 is switched back into automatic mode. Automatic mode is also re-established if the PC tool is disconnected from the Bosch PowerBox PBX 180. Manual Output Mode, Keep Current States When this option is selected, Bosch PowerBox PBX 180 is in manual operating mode, but keeps its setting from the instant when it is switched into manual mode. Any output which were switched on, remains on in this mode, but can be switched off manually if required. 10 / 60 PowerBox PBX 180 Bosch Motorsport

11 Main Menu Get Time Click Get Time to read date and time from Bosch PowerBox PBX 180 s real time clock. Set Time Click Set Time to update Bosch PowerBox PBX 180 s real time clock with the date and time from the PC connected. Ensure that your PC clock has the required time. Reset Output Counters Click this option to reset all diagnostic counters and error messages. Interface Click Interface and then select the USB-CAN interface in use. Once the right interface is selected, communication will be established between Bosch PowerBox PBX 180 and the PC tool. No other action is required. These interfaces are currently supported: CAN USB Adapter (Lawicel) Peak CAN Adapter (Peak Systems, recommended) EFI Technology CAN Adapter Status of Bosch PowerBox PBX 180 communication is displayed in the tool by a colored LED in the upper right hand corner: Purple: No or incorrect interface connected. Red: No CAN communication. Green: CAN communication OK. 4.4 Options Reset Display on Disconnect Tick this option to retain display information on display screens when disconnecting from Bosch PowerBox PBX 180. This can be a help, for example, in detecting and understanding a possible malfunction. Bosch Motorsport PowerBox PBX / 60

12 4 Main Menu Sync Time Automatically Tick this option to synchronize the time and date between Bosch PowerBox PBX 180 and the PC. 4.5 Help Click HELP to open the Bosch PowerBox PBX 180 help file. Use F1 as a hot key to open the help file. (Feature not implemented in this release). 12 / 60 PowerBox PBX 180 Bosch Motorsport

13 Functions 5 5 Functions The Bosch PowerBox PBX 180 PC tool is divided into sub sections. When the program opens, it displays the Overview section by default. 5.1 Overview This section displays the following Bosch PowerBox PBX 180 information: Serial Number Bosch PowerBox PBX 180 production serial number Intended Serial Number The actual configuration can only be used with a Bosch PowerBox PBX 180 having this serial number. Hardware version Bosch PowerBox PBX 180 hardware release version Power Box Name Reference name for actual PowerBox. Maximum 15 characters can be used. The PC tool release version is also displayed in this section, see Configuration Utility Version. 5.2 Units Use this section to assign a unit to analogue and CAN channels. These settings can be applied in INPUTS, sections Analogue Inputs and CAN Inputs. Bosch Motorsport PowerBox PBX / 60

14 5 Functions Events Bosch PowerBox PBX 180 is controlled by configurable events. Events are used to create conditions, simple as well as complex logic conditions. For example, an output can be controlled by a single event or by a complex string of events. 512 individual events are available and each can be defined as a specific type: For example, a digital input can switch a single output using a single event, or by a complex string of events. Please note that an output must be controlled by a single event. Event Type Select between the following types of control strategies. Input follow Name the event to make it easy to trace it later. Select the input trigger for the event. Set the conditions for switching between true and false. For example, selecting a digital input, the event is ON when the switch is ON. It is OFF when the digital switch is OFF. Select the output to trigger. Select NONE if this is a conditional event only. Input toggle Name the event to make it easy to trace it later. Select the input trigger for the event. Set the conditions for switching between true and false. For example, selecting a digital input, the event will switch ON when the switch is pressed momentary ON. It will switch OFF when the digital switch is pressed again momentary. Select the output to trigger. Select NONE if this is a conditional event only. 14 / 60 PowerBox PBX 180 Bosch Motorsport

15 Functions 5 AND gate The AND gate combines up to five events to set switching conditions. All added events have to be true for the final event to be true. Select the output to trigger. Select NONE if this is a conditional event only. OR gate The OR gate combines up to five events to set switching conditions. Any of the added events have to be true for the final event to be true. Select the output to trigger. Select NONE if this is a conditional event only. NOR gate The NOR gate combines up to five events to set switching conditions. If any of the added events are true, the final event will be false. Select the output to trigger. Select NONE if this is a conditional event only. XOR gate The XOR gate combines up to five events to set switching conditions. When one and only one of the added events are true, the final event will be true. Select the output to trigger. Select NONE if this is a conditional event only. NOT gate The NOT gate inverts a single input event. Select the output to trigger. Select NONE if this is a conditional event only. Flash Defining a flash event it is possible to set: Time ON (how long time is the output switched ON) Time OFF(how long time is the output switched OFF) Initial status, ON or OFF (Flash starts with output switched ON or OFF) Select the output to trigger. Select NONE if this is a conditional event only. Delay input ON Using this event it is possible to set a delay timer for switching the event to true. Delay input OFF Using this event it is possible to set a delay timer for switching the event from true to false. Counter This event is currently not activated. Sequence counter This event is currently not activated. Bosch Motorsport PowerBox PBX / 60

16 5 Functions Reset Use this event to define a reset function for output channels. The reset function will restart outputs which are in a fault status only. No other channels are influenced. The reset function can be used with any input or output and any channel status or current draw. A typical installation combines the fault warning light and a reset switch. Bosch PowerBox PBX 180 has a dedicated output for a fault warning light. Pin 42 in connector #4 provides a 5 V signal out in case one of the output channels goes into a fault mode. It is recommended to use a LED with a 1 kohm resistor in-line as a warning light. Our normal reset function is based on grounding this warning light signal when ON. We can supply a combined switch and a 5 V LED warning light. Creating a Reset event, proceed this way: Select RESET as an even type. Name the event, for example RESET. Select Fault Warning Lamp as source input Set Turn ON as >1 Set Turn OFF as < 2 Refer to section Output Diagnostics for fault message codes. Clock Use this event to link the switching to the real time clock. Always ON Use this event to switch the event to true once power is applied to the Bosch PowerBox PBX 180, for example when the master switch is ON. Tri-state output The tri-state outputs are used as triggers for external systems. Their value can change between 0 V, 2.5 V and 5.0 V. Do not expose these outputs to any load, they are trigger channels only. Please note that if both selectable trigger events (A and B) are true, the output will be 5 V. 16 / 60 PowerBox PBX 180 Bosch Motorsport

17 Functions 5 Wiper output Two dedicated wiper channels are available. These channels are fitted with braking diodes, ensuring the wipers stop when the park signal is detected. Create an event for the park signal. The park signal can be either a ground or battery power signal. Import this event as the Stop event. Select an input to trigger the wiper. When this input is switched OFF, the wiper motor will continue running until the park signal is detected. Event Flash Use this function if an event is required to trigger the flash function. Event Delay On Use this function if it is required to delay switching an event controlled output ON. Event Delay Off Use this function if it is required to delay switching an event controlled output OFF. Bosch Motorsport PowerBox PBX / 60

18 5 Functions Event Wiper The wiper function can also be controlled by an event instead of a direct input as before. Using this function makes it possible to combine wiper strategies, for example combining the wipe wash and wipe delay with normal wiper function Event Name Name the event for easy identification Source Input Select the input controlling this event. Inputs can be: Digital inputs Analogue inputs Current draws Fault status CAN inputs (from all four CAN bus) (CAN bus 1+2 only implemented in this version) Counters Temperature CAN Inputs Lost CAN Action For safety reasons it is possible to set conditions for channels controlled via CAN. If the CAN bus communication is lost at any time for a defined time interval (in milliseconds) the following actions can be defined, individually for each CAN event: Do nothing (keep current status) 18 / 60 PowerBox PBX 180 Bosch Motorsport

19 Functions 5 Turn Off (switch the output channel off) Turn On (switch the output on) CAN Lost Timer This defines a time interval for receiving CAN messages. If a given CAN message is not updated within the time interval, the system considers the CAN bus has gone into fault mode. DO NOT SET THIS INTERVAL TO 0 (ZERO)! It is recommended to use an interval of app. 2.5 times the message update rate. For example, if the update interval is 100 msec, it is recommended to set the time interval to 250 msec. During this time interval the system should recognize 2 messages, confirming the CAN bus is functioning Turn ON / Turn OFF Select the conditions for switching ON (or OFF): = Equal to < Less than > Greater than <= Less than or equal to >= Greater than or equal to!= Not equal to Output Select which output this event controls. Select NONE if this is a conditioning event which is part of a logic switch string. It is essential that only one (1) event controls a given output. If multiple switching conditions apply, these must be joined in a single, final event, for example an AND, OR, etc event, Miscellaneous Use this section to set: Bosch PowerBox PBX 180 minimum voltage (recommended set to 6,000 mv) The battery voltage level has to drop below the low threshold for 10 seconds before outputs are switched off. The voltage level has to rise above the minimum voltage level plus 0.5 V for mini-mum 10 seconds before outputs are turned on again. Bosch PowerBox PBX 180 maximum voltage (set to 24,000 mv) Special Functions It is possible to assign outputs to switch ON or to switch OFF when specific events are selected. For example, to maximize engine cranking speed and to preserve battery power Bosch PowerBox PBX 180 can be configured to disable other outputs whilst the starter motor is activated. Create an event for activating the Bosch Motorsport PowerBox PBX / 60

20 5 Functions starter solenoid. Select this event as for example EVENT 01 in section SPECIAL OFF. Open the output map and select which outputs to switch OFF (if ON) when the starter is activated. Click on Set Output Map to open the configuration tables. Each output can be linked to 8 condition-ing events. To turn a specific output off when the input event is true tick the box for the outputs as shown. Please note, that special function maps have overall priority over any event controlled function Counters This function is not yet implemented. Status This section displays the general Bosch PowerBox PBX 180 status: Status for digital switches are shown as Open, Low or High Analogue channels displays sensor input voltage Bosch PowerBox PBX 180 on-board temperature measurement in C on signal and power boards Tri-state output voltages Real time current draws for low, high and very high outputs Status of the three analogue sensor reference voltage supply (VREF) Warning light status CAN channels displays decimal channel values. Counters are not yet implemented. Warning Light Status The warning light will flash error codes, making it easy to trace an eventual fault: 1 flash Error on CAN 1 (you can select in tool if you want to enable this option).displays value "1" in tool on status page. 2 flashes Error on CAN 2 (you can select in tool if you want to enable this option).displays value "2" in tool on status page. 3 flashes Error on CAN 3 (you can select in tool if you want to enable this option).displays value "4" in tool on status page. 20 / 60 PowerBox PBX 180 Bosch Motorsport

21 Functions 5 4 flashes Error on CAN 4 (you can select in tool if you want to enable this option). Displays value "8" in tool on status page 5 flashes Power output. Displays value "16" in tool on status page. 6 flashes Miscellaneous output. Displays value "32" in tool on status page. 7 flashes Real time clock. Displays value "64" in tool on status page. 8 flashes Faulty configuration. Displays value "128" in tool on status page. This diagnostics can also display a combination of errors Events Monitor This section displays the status of Bosch PowerBox PBX 180 events. Green resembles a TRUE event. Blue resembles a FALSE event. Output Diagnostics This section displays the Bosch PowerBox PBX 180 system diagnostic: The columns illustrate: Current Actual real time current draw, updates when the tool is connected and the current draw changes, measured in steps of 100 ma. Bosch Motorsport PowerBox PBX / 60

22 5 Functions Peak Highest recorded peak current. OCL Number of times the output current draw has exceeded the user-defined Over Current Low threshold (low hardware setting). OCH Number of times the output current draw has exceeded the fixed Over Current High setting (75 A in LP, 100 A in HP). OCS Number of times the output current draw has exceeded the software threshold, Over Current Soft, the fuse value. Thm Thermal shut down due to high junction temperatures. Stat Status of output channel: Fault Status Hex Value STATUS_OUTPUT_OFF_OK 0x STATUS_OUPTUT_ON_OK 0x STATUS_OUTPUT_SHUTDOWN_OVER_VOLTAGE 0x STATUS_OUTPUT_SHUTDOWN_UNDER_VOLTAGE 0x STATUS_OUTPUT_SHUTDOWN_OPEN_LOAD 0x STATUS_OUTPUT_SHUTDOWN_OVER_CURRENT_LOW 0x STATUS_OUTPUT_SHUTDOWN_OVER_CURRENT_HIGH 0x STATUS_OUTPUT_SHUTDOWN_OVER_THERMAL 0x STATUS_OUTPUT_SHUTDOWN_OVER_SOFT_CURRENT 0x STATUS_OUTPUT_SHUTDOWN_OVER_SOFT_CURRENT_RE- TRY Channels not supported are: Low power 29, 30, 31 and 32. All PWM channels All tri-state outputs All VREF sensor supplies Value Description 0 Channel switched off. 1 Channel switched on. 8 Channel switched off and has no load connected to it. 0x Decimal Value 22 / 60 PowerBox PBX 180 Bosch Motorsport

23 Functions 5 Error status codes are normally shown as a combination of numbers: Value Description 17 Bosch PowerBox PBX 180 is trying to switch the channel on, but the current draw has exceeded the low hardware (OCL) threshold and has gone into an error status. 33 Bosch PowerBox PBX 180 is trying to switch the channel on, but the current draw has exceeded the high hardware (OCH) threshold and has gone into an error status. 129 Bosch PowerBox PBX 180 is trying to switch the channel on, but the current draw has exceeded the software (OCS) threshold and has gone into an error status. Using the Reset event to reset any outputs in error status does not clear this diagnostic. Only channels which have failed will be reset. In general, switching a channel OFF then ON will attempt a restart, even if the channel has failed earlier. To clear diagnostic, look in the tools main menu in "Device". Clicking on "Reset Output Counters" will reset diagnostics. Bosch Motorsport PowerBox PBX / 60

24 6 Inputs Inputs Bosch PowerBox PBX 180 has 14 digital and 16 analogue inputs. These inputs can be used with sensors or switches. Furthermore, Bosch PowerBox PBX 180 has 4 individual CAN lines with a maximum of 64 CAN channels and unlimited assigning of identifiers. Bosch PowerBox PBX 180 is fitted with 2 internal temperature sensors for system monitoring. Digital Inputs 14 digital inputs are available as switch inputs, but can also be assigned as wheel speed sensor inputs, for example. The intention with the Bosch PowerBox PBX 180 is to simplify the wiring installation as much as possible. If you use the digital inputs for external toggle switches, you have to connect up to 14 signal wires to the module. But if you choose to control Bosch PowerBox PBX 180 via CAN, you can control all functions via a 2-wire data bus for each CAN bus. Input names can be up to 15 characters long. Digital inputs can be triggered by: Connecting to ground Connecting to open circuit Connecting to battery voltage Configuration of switch condition is set within the event handling. Defining whether an input is considered latching or momentary is also done within the event han-dling. Set the minimum debounce time required for the system to acknowledge a switch signal. If a digital input is used with a speed sensor, the sensor must be a Hall effect sensor. Channel status is displayed. Pin Configuration Digital Inputs: Digital Input Connector 4 Pin 1 AS SN 8 2 AS SN 7 3 AS SN 3 4 AS SN 13 5 AS SN 2 6 AS SN 6 7 AS SN 1 8 AS SN 12 9 AS SN 5 10 AS SN AS SN 4 12 AS SN AS SN AS SN / 60 PowerBox PBX 180 Bosch Motorsport

25 Inputs Analogue Inputs Bosch PowerBox PBX 180 has 16 analogue 0 to 12 V sensor inputs with a 16 bit resolution. Fur-thermore, these inputs can be grouped to create 8 differential inputs (not implemented yet). Input names can be up to 15 characters long. Analogue inputs can be assigned having different characteristics: Pull-up to VREF through a 3,16 kohm resistor (for use with NTC temperature sensors) Pull-up to VREF through a 47 kohm resistor Floating input Section Conversion gives access to a linearization table having 32 breakpoints. Any number of breakpoints can be used, a 2-point calibration of a pressure sensor only requires two. If a sensor A/D value is below the minimum breakpoint, the minimum value is applied. If a sensor A/D value is above the maximum breakpoint, the maximum value is applied. Leaving all breakpoints at 0 (zero) channel values are displayed in mv. Sensor scaling is normally entered in for example mbar, ml, ma etc. Use the column Divisor to scale mbar to bar etc. Sensor channel values are displayed in real time in both raw and scaled sensor values. Please note that the analogue inputs are disabled in the instant when power to the Bosch PowerBox PBX 180 is switched off. Pin Configuration Analogue Inputs: Analogue Input Connector 4 Pin 1 AS SN 48 2 AS SN 49 3 AS SN 53 Bosch Motorsport PowerBox PBX / 60

26 6 Inputs 4 AS SN 43 5 AS SN 54 6 AS SN 50 7 AS SN 55 8 AS SN 44 9 AS SN AS SN AS SN AS SN AS SN AS SN AS SN AS SN CAN Inputs Bosch PowerBox PBX 180 has 4 individual CAN busses. Each CAN bus can be defined as 11 or 29 bit identifier. Additionally, each of these 4 CAN bus can be individually terminated and the baud rate for each is selectable. Each of the 64 available CAN inputs can be named as required. Select on which of the four CAN bus the actual channel is found. Set the identifier in which the actual channel is included. This value must be in hex, for example 0x119. Select the unit of the channel, for example RPM, bar, deg etc, Section Set Points gives access to a linearization table having 32 breakpoints. Any number of breakpoints can be used, a 2-point calibration of a pressure sensor only requires two. If a sensor A/D value is below the minimum breakpoint, the minimum value is applied. If a sensor A/D value is above the maximum breakpoint, the maximum value is applied. Leaving all breakpoints at 0 (zero) channel values are displayed in bits (for channels sent as byte or word) or in a decimal value (if the channel is transmitting bit values). 26 / 60 PowerBox PBX 180 Bosch Motorsport

27 Inputs 6 For each individual CAN bus there is no limitation to the numbers of CAN identifiers selected. Each of the 64 available CAN inputs can use a unique identifier. Identifiers do not have to be arranged in special groups. CAN channels can contain a switch status, 8 bit data channels or 16 bit data channels. A typical switch status uses the individual 8 bits within a single byte. An 8 bit data channel reads data in the range between 0 and 255 and uses 1 byte. A 16 bit data channel reads data in the range between 0 and and uses 2 bytes. 16 bit channels can be arranged as either Big Endian (Motorola format) or Little Endian (Intel format). When configured as Big Endian the two bytes are arranged as [(MSB); (LSB)], for example byte 0 is High (MSB) and byte 1 is Low (LSB). When configured as Little Endian the two bytes are arranged as [(LSB); (MSB)]. Bit management within each of the 8 bytes is available. Each byte contains 8 bits which are numbered this way: Byte 0 = 0 to 7 bits Byte 1 = 8 to 15 bits Byte 2 = 16 to 23 bits Byte 3 = 24 to 31 bits Byte 4 = 32 to 39 bits Byte 5 = 40 to 47 bits Byte 6 = 48 to 55 bits Byte 7 = 56 to 63 bits Using bit wise operator it is possible to address for example status of 8 individual switches. The decimal values of the bits in a byte are: Bit 0 = 1 Bosch Motorsport PowerBox PBX / 60

28 6 Inputs Bit 1 = 2 Bit 2 = 4 Bit 3 = 8 Bit 4 = 16 Bit 5 = 32 Bit 6 = 64 Bit 7 = 128 Example: To read the data from bit 4 in byte 1 of a given identifier proceed this way: 1. In section Low Byte un-tick Bit Selection OR Byte Selection 2. Click on the arrow down and select the byte containing the data information, for example byte 1 3. Tick Bit Selection OR Byte Selection 4. Deselect reading of data from bits 0, 1, 2, 3, 5, 6 and 7 by selecting the option - - from the scroll down menu for each of these bits. 5. An easy way to proceed is to click once on one of the bit windows, then press END (now the se-lection - - is displayed). Using the TAB key jump to the next bit, press END, then the TAB key again etc. 6. Leave bit 4 on the value of 12. Bosch PowerBox PBX 180 will detect and report an eventual short circuit of a CAN bus. After a short circuit the CAN bus will reset. Pin Configuration for CAN Communication: Name Connector 4 Pin CAN1 H AS SN 24 CAN1 L AS SN 23 CAN2 H AS SN 16 CAN2 L AS SN 15 CAN3 H AS SN 9 CAN3 L AS SN 22 CAN4 H AS SN 14 CAN4 L AS SN / 60 PowerBox PBX 180 Bosch Motorsport

29 Outputs Outputs Bosch PowerBox PBX 180 has 48 power channels with current measurement plus 4 analogue trigger outputs. All power outputs are designed for use in harsh environments and include self-recovery features. Outputs are designed to handle loads with high inrush current as well as motors and all types of resistive and inductive loads. All outputs are protected against reversed battery polarity and too high temperatures. The power channels are divided into groups: Low power outputs (ON/OFF switches) Low power wiper outputs (ON/OFF switches) with recirculation diodes Low power outputs with pulse width modulation (PWM) (frequency controlled duty cycle) High power outputs (ON/OFF switches) High power outputs with pulse width modulation (PWM) (frequency controlled duty cycle) Very high power outputs (ON/OFF switches) The tri-state analogue outputs cannot be used as power supplies; they can only be used as trigger signals. Please note that the current draw per channel is limited by the connector not by the driver stages. We have rated the individual channel s current draw in relation to the connector manufacturer s specifications. Tri-State Outputs Tri-state outputs cannot be used as power supplies. They are designed as logic switches and are used only as trigger signals for analogue inputs on other modules, for example an ECU. They are controlled by the event handling and the output signals can have these values: 0 V 2.5 V 5.0 V Please read also the description from tri-state event in Events section. Tri-state Max current, A Connector 3 Pin 1 - AS SA Y 2 - AS SA B 3 - AS SA Z 4 - AS SA C 7.2 Low Power Outputs This section gives access to: Bosch Motorsport PowerBox PBX / 60

30 7 Outputs Naming of output Set inrush current threshold Set time interval for inrush current Set the normal fused threshold Set the number of retries once a fault is detected before switching off Set the time interval for fault resetting 26 low power outputs are available, supplying a maximum continuous current of 8 A each chan-nel. Please observe that our recommended current rating each channel is given in accordance with Deutsch s current limit for the size AWG20 contacts in the Autosport connector. Current draw can be measured on all outputs. On outputs 1 to 22 current can be measured from 200 ma to full load. Outputs 23 to 26 all have increased resolution making them a preferred selec-tion for lift pumps, for example. The driver stages can deliver significantly more current, but it is important to avoid overloading the wiring and contacts in the connector. Once an output is turned on, the current draw depends on the attached load. If this load is a resistive load, there will hardly be any inrush current. If the output drives a motor or a lamp, for example, there can be a substantial inrush for a certain amount of time. The current draw will quickly decrease and reach a steady state level. Outputs are protected by three current thresholds and three timers: OCH is the high current threshold of 75 A. OCL is the user defined continuous current threshold. This level is selectable between 7.5 A to 12.5 A. OCS is the software selected current threshold. 30 / 60 PowerBox PBX 180 Bosch Motorsport

31 Outputs 7 1. Switching an output ON, an inrush current up to and in excess of 75 A is allowed for a 20 usec time interval. 2. After these 20 usec the current level must be below OCH which is 75 A. 3. Within a time interval, selectable between 0.15 to 155 msec, from switching the output ON, the current draw must have fallen below the OCL threshold. This threshold can be set to 7.5 A, 10 A, 12.5 A. 4. In column INIT ms key in the time delay for applying the steady state fuse level defined in NORM ma. This interval must exceed the time interval selected for OCL, suggested value > 200 msec. Maximum time is limited to 10 seconds. 5. After the time interval INIT, the initial time from switching the output ON, the current draw must be below the user defined software fuse level, OCS. If the current draw exceeds this threshold, the output will be switched off. 6. In column NORM ma key in the steady state fuse level required. This value must be lower than the maximum fuse level, OCL. Maximum current threshold is 13,000 ma. 7. If the current draw on an output exceeds the NORM fuse setting, the output will switch off. 8. In Retry set the maximum number of automatic re-activation of an output channel after is has been shut down caused by a short circuit or an overload. It is strongly recommended not to ex-aggerate the number of retries select a number < In Retry ms set the time interval between retries in milliseconds. 10. The status window will show the real time current draw of the output in ma. 11. Use the Manual option to test the output connection. When Manual is active, Bosch PowerBox PBX 180 s event handling has been deactivated and all channels are OFF by default. 12. Click the ON button for each individual channel to switch the output ON. 13. Click the ON button again to switch the output OFF. 14. Clicking on Trigger will open the main event controlling this output. A warning may appear if several events are used to control it. LP OUT Max current, A Connector 3 Pin 1 8 AS SA e 2 8 AS SA N 3 8 AS SA f Bosch Motorsport PowerBox PBX / 60

32 7 Outputs 4 8 AS SA P 5 8 AS SA q 6 8 AS SA R 7 8 AS SA g 8 8 AS SA S 9 8 AS SA h 10 8 AS SA T 11 8 AS SA i 12 8 AS SA U 13 8 AS SA d 14 8 AS SA K 15 8 AS SA n 16 8 AS SA L 17 8 AS SA p 18 8 AS SA M 19 8 AS SA c 20 8 AS SA J 21 8 AS SA G 22 8 AS SA H 23 8 (high resolution current measurement) AS SA F 24 8 (high resolution current measurement) AS SA b 25 8 (high resolution current measurement) AS SA D 26 8 (high resolution current measurement) AS SA E 7.3 Low Power PWM Outputs This section gives access to: Naming of output Set inrush current threshold Set time interval for inrush current Set the normal fused threshold Set the number of retries once a fault is detected before switching off Set the time interval for fault resetting Select the type of PWM applied Define duty cycle or frequency map 4 low power outputs are available with PWM capability applying frequencies from 30 Hz up to 25 khz and of supplying a maximum, recommended continuous current of 8 A each channel. Please observe that our recommended maximum current rating for each of these four channels is given in accordance with 32 / 60 PowerBox PBX 180 Bosch Motorsport

33 Outputs 7 Deutsch s current limit for the size AWG20 contacts in the Autosport connector. The driver stages can deliver significantly more current, but it is important to avoid overloading the wiring and contacts in the connector. Warning Do not connect PWM output channels in parallel. Current draw can be measured on all outputs and displays the maximum current draw, neglecting the OFF periods. Outputs are protected by three current thresholds and three timers: OCH is the high current threshold of 75 A. OCL is the user defined continuous current threshold. This level is selectable between 7.5 A to 12.5 A. OCS is the software selected current threshold. Switching an output ON, an inrush current up to and in excess of 75 A is allowed for a 20 usec time interval. After these 20 usec the current level must be below OCH which is 75 A. Within a time interval, selectable between 0.15 to 155 msec, from switching the output ON, the current draw must have fallen below the OCL threshold. This threshold can be set to 7.5 A, 10 A, 12.5 A. In column INIT ms key in the time delay for applying the steady state fuse level defined in NORM ma. This interval must exceed the time interval selected for OCL, suggested value > 200 msec. Maximum time is limited to 10 seconds. After the time interval INIT, the initial time from switching the output ON, the current draw must be below the user defined software fuse level, OCS. If the current draw exceeds this threshold, the output will be switched off. Bosch Motorsport PowerBox PBX / 60

34 7 Outputs In column NORM ma key in the steady state fuse level required. This value must be lower than the maximum fuse level, OCL. Maximum current threshold is 13,000 ma. If the current draw on an output exceeds the NORM fuse setting, the output will switch off. In Retry set the maximum number of automatic re-activation of an output channel after is has been shut down caused by a short circuit or an overload. It is strongly recommended not to ex-aggerate the number of retries select a number < 10. In Retry ms set the time interval between retries in milliseconds. PWM Type is used to define the functionality of the PWM feature: PWM Type None PWM Feature Output disabled Dig out No PWM used, output is off or on 100% Duty intrp Duty down Duty up Duty near Freq intpr Freq down Freq up Freq near Interpolation between duty cycle breakpoints Duty cycle from nearest lower breakpoint applied Duty cycle from nearest higher breakpoint applied Duty cycle from nearest lower or higher breakpoint applied Interpolation between frequency breakpoints Frequency from nearest lower breakpoint applied Frequency from nearest higher breakpoint applied Frequency from nearest lower or higher breakpoint applied The frequency option is only available on LP PWM3 and LP PWM Duty Cycle Maps Duty cycle maps are designed with variables on both X and Y axis. Use the drop down menus to select the channels used for the X and Y axis of the table. 34 / 60 PowerBox PBX 180 Bosch Motorsport

35 Outputs 7 It is not necessary to use the full table and all breakpoints in the maps nor to use both axis's. Using a two-axis calibration, start filling the map out from upper left hand corner. Using a single axis calibration, select the X or Y-axis as the input reference, using only the first row or column of the other axis. The map can be imported and exported to Excel. An easy way to create a duty cycle map is to follow this procedure: 1. Open the duty cycle map. 2. Click Copy. 3. Paste into Excel. 4. Modify table. 5. Mark the table and copy. 6. Return to the tool and click past. 7. Set frequency in Hz; minimum applied value is 30 Hz, maximum value is 15 khz. Please note that LP PWM1 and LP PWM2 must use the same frequency! Frequency Maps Frequency maps are single axis maps; the duty cycle percentage must be kept constant. Please note that frequency mapping is only available on LP PWM3 and LP PWM4. Use the drop down menus to select the channel used for the single axis of the table. The map can be imported and exported to Excel. An easy way to create a frequency map is to follow this procedure: 1. Open the frequency map. 2. Click Copy. 3. Paste into Excel. 4. Modify table. 5. Mark the table and copy. 6. Return to the tool and click past. 7. Set the applied duty cycle percentage; values can be between 5 and 99%. The Status window shows the real time current draw of the output in ma. 8. Use the Manual option to test the output connection. When Manual is active (see section 4.3), Bosch PowerBox PBX 180 s event handling has been deactivated and all channels are OFF by default. 9. Click the ON button for each individual channel to switch the output ON. Bosch Motorsport PowerBox PBX / 60

36 7 Outputs 10. Click the ON button again to switch the output OFF. 11. Clicking on Trigger will open the main event controlling this output. A warning may appear if several events are used to control it. The status window will show the real time current draw of the output in ma. 12. Use the Manual option to test the output connection. When Manual is active (see section 4.3), Bosch PowerBox PBX 180 s event handling has been deactivated and all channels are OFF by default. 13. Click the ON button for each individual channel to switch the output ON. 14. Click the ON button again to switch the output OFF. 15. Clicking on Trigger will open the main event controlling this output. A warning may appear if several events are used to control it. LP PWM OUT Max current, A Connector 3 Pin 1 8 AS SA k 2 8 AS SA V 3 8 AS SA j 4 8 AS SA W 7.4 High Power Outputs This section gives access to: Naming of output Set inrush current threshold Set time interval for inrush current Set the normal fused threshold Set the number of retries once a fault is detected before switching off Set the time interval for fault resetting 12 high power outputs are available, supplying a maximum continuous current of 20 A each channel. Please observe that our recommended current rating each channel is given in accordance with Deutsch s current limit for the size AWG16 contacts in the Autosport connector. Current draw can be measured on all outputs. 36 / 60 PowerBox PBX 180 Bosch Motorsport

37 Outputs 7 The driver stages can deliver significantly more current, but it is important to avoid overloading the wiring and contacts in the connector. Once an output is turned on, the current draw depends on the attached load. If this load is a resistive load, there will hardly be any inrush current. If the output drives a motor or a lamp, for example, there can be a substantial inrush for a certain amount of time. The current draw will quickly decrease and reach a steady state level. Outputs are protected by three current thresholds and three timers: OCH is the high current threshold of 100 A. OCL is the user defined continuous current threshold. This level is selectable as 15 A, 20 A or 25 A. OCS is the software selected current threshold. 1. Switching an output ON, an inrush current up to and in excess of 100 A is allowed for a 20 usec time interval. 2. After these 20 usec the current level must be below OCH which is 100 A. 3. Within a time interval, selectable between 0.15 to 155 msec, from switching the output ON, the current draw must have fallen below the OCL threshold. This threshold can be set to 15 A, 20 A, 25 A. 4. In column INIT ms key in the time delay for applying the steady state fuse level defined in NORM ma. This interval must exceed the time interval selected for OCL, suggested value > 200 msec. 5. Maximum time is limited to 10 seconds. 6. After the time interval INIT, the initial time from switching the output ON, the current draw must be below the user defined software fuse level, OCS. If the current draw exceeds this threshold, the output will be switched off. 7. In column NORM ma key in the steady state fuse level required. This value must be lower than the maximum fuse level, OCL. Maximum current threshold is 26,000 ma. 8. If the current draw on an output exceeds the NORM fuse setting, the output will switch off. 9. In Retry set the maximum number of automatic re-activation of an output channel after is has been shut down caused by a short circuit or an overload. It is strongly recommended not to ex-aggerate the number of retries select a number < In Retry ms set the time interval between retries in milliseconds. Bosch Motorsport PowerBox PBX / 60

38 7 Outputs 11. The status window will show the real time current draw of the output in ma. 12. Use the Manual option to test the output connection. When Manual is active (see section 4.3), Bosch PowerBox PBX 180 s event handling has been deactivated and all channels are OFF by default. 13. Click the ON button for each individual channel to switch the output ON. 14. Click the ON button again to switch the output OFF. 15. Clicking on Trigger will open the main event controlling this output. A warning may appear if several events are used to control it. Channel Max current, A Connector 4 Pin 3 20 AS SN M 4 20 AS SN K 5 20 AS SN F 6 20 AS SN N 7 20 AS SN R 8 20 AS SN S 9 20 AS SN D AS SN A AS SN L AS SN J 7.5 Very High Power This section gives access to: Naming of output Set inrush current threshold Set time interval for inrush current Set the normal fused threshold Set the number of retries once a fault is detected before switching off Set the time interval for fault resetting 2 very high power outputs are available, supplying a maximum continuous current of 20 A each channel. Please observe that our recommended current rating each channel is given in accordance with Deutsch s current limit for the size AWG16 contacts in the Autosport connector. Current draw can be measured on all outputs. 38 / 60 PowerBox PBX 180 Bosch Motorsport